Print precision improvement over long print jobs

ABSTRACT

A method and apparatus for printer compensation is disclosed. A label stop sensor (LSS) detects a time T(1) associated with an initial label position near the beginning of a print job. The label stop sensor detects a time T(L) associated with a label position that is L labels later in the print job. From at least the times T(1) and T(L) and a printer media feed rate a processor calculates a difference between the initial label position and the later label position. A start adjustment factor is compensated by the difference between the initial label position and the later label position to account for changes in print position between the first label and the later label.

FIELD OF THE INVENTION

The present invention relates to improving the precision of printing over the course of long print jobs.

BACKGROUND

With label printers and the like that utilize rolled pint media, often a shift in the print position on a label often drifts over the course of a long print job. The shift in the print position is due to the change in diameter of the roll of print media as the labels are pulled from the roll by spring force for printing. The pulling force on a new roll of print media differs from that of a used roll (due to the different diameter of the print media). In existing printers, there is no mechanism to manage this changing force. As a result, print can shift over the course of a long print job.

Referring to FIG. 1, an example is shown of how printing degrades from the first few labels 20, 22 and 24 affixed to a label release liner 28 in a print job to labels later in a print job (i.e., such as 1000 labels later) such as labels 30 and 32 where the printed text may no longer align within the label boundaries. In this illustration, the labels and liner move through the printer in the direction shown by arrow 26. Such drift in printing is wasteful and may require that all or portions of a print job be repeated. At the end of a very long print job, the labels may be useless.

Therefore, a need exists for a mechanism to improve the precision of print alignment for long print jobs.

SUMMARY

Accordingly, in certain example embodiments, a method of printer compensation, involves: using a sensor, detecting a time T(1) associated with an first label position; using the sensor, detecting a time T(L) associated with a label position that is L labels later in a print job; from at least the times T(1) and T(L) and a media feed rate, calculating a difference between the first label position and the second label position; and compensating an adjustment factor by the difference between the first label position and the second label position to account for changes in print position.

In certain example embodiments, the calculating comprises converting times T(1) and T(L) to a distance. In certain example embodiments, the calculating comprises converting times T(1) and T(L) to a distance represented in printed dots in a feed direction. In certain example embodiments, detecting the value T(1) further comprises detecting a sequence of M values T(1) through T(M). In certain example embodiments, detecting the value of T(L) further comprises detecting a sequence of M adjacent values about label L. In certain example embodiments, the process further involves averaging the values of T(1) through T(M) to produce TA(1); and averaging the values of the M adjacent values about label L to produce TA(L).

In certain example embodiments, the calculating includes from at least the times TA(1) and TA(L), and a feed rate, calculating a difference between the first label position and the second label position. In certain example embodiments, the process includes converting the M values T(1) through T(M) to distances D(1) through D(M); and converting the M adjacent values about label L to M distances D(L−M) through D(L). In certain example embodiments, the process further involves averaging the values of D(1) through D(L) to produce DA(1); and averaging the values of the M adjacent values about label L to produce DA(L). In certain example embodiments, the calculating comprises using the distances DA(1) and DA(L) to calculate a difference between the first label position and the second label position.

In another example embodiment, a method of printer compensation involves using a sensor detecting a sequence of time values T(1) through T(M) associated with an first label position; converting the M values T(1) through T(M) to distances D(1) through D(M); using the sensor, detecting times T(L−M) through T(L) associated with a M label positions that are approximately L labels later in the print job; converting the M adjacent values about label L to L distances D(L−M) through D(L); averaging the values of D(1) through D(M) to produce DA(1); averaging the values of D(L−M) through D(L) to produce DA(L); from at least the distances DA(1) and DA(L), calculating a difference between the first label position and the second label position; and compensating an adjustment factor by the difference between the first label position and the second label position to account for changes in print position.

In certain example embodiments, the distances are represented in printed dots in a feed direction.

In another example embodiment, a label printer device, has a sensor that detects a transition between labels. A processor receives and interprets signals from the sensor. A motor advances a label medium through the printer. The processor is programmed to: use the sensor to detect a time T(1) associated with an first label position; use the sensor to detect a time T(L) associated with a label position that is L labels later in the print job; from at least the times T(1) and T(L), and a printer feed rate, calculate a difference between the first label position and the second label position; and compensate an adjustment factor by the difference between the first label position and the second label position to account for changes in print position.

In certain example embodiments, the transition comprises at least one of a space, black mark, hole, or optical element. In certain example embodiments, the processor is programmed to convert times T(1) and T(L) to distances. In certain example embodiments, the processor: in detecting the value T(1) is further programmed to detect a sequence of M values T(1) through T(M); and in detecting the value of T(L) is further programmed to detect a sequence of M adjacent values about label L. In certain example embodiments, the processor is further programmed to: average the values of T(1) through T(M) to produce TA(1); average the values of the M adjacent values about label L to produce TA(L); and calculate from at least the times TA(1) and TA(L), and a printer media feed rate a difference between the first label position and the second label position.

In certain example embodiments, the processor is programmed to: convert the M values T(1) through T(M) to distances D(1) through D(M); convert the M adjacent values about label L to M distances D(L−M) through D(L); average the values of D(1) through D(M) to produce DA(1); and average the values of the M adjacent values about label L to produce DA(L). In certain example embodiments, the processor is programmed to calculate a difference between the distances DA(1) and DA(L) to calculate a difference between the first label position and the second label position. In certain example embodiments, the distances DA(1) and DA(L) are represented as a number of printed dots in a feed direction. In certain example embodiments, the processor is programmed to carry out the compensating by adjusting a value of an adjustment factor.

The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts an example of a sequence of printed labels in which the print position has drifted.

FIG. 2 is an example of a portion of a printer consistent with certain example embodiments of the present invention.

FIG. 3 is a first example of the output of a LSS consistent with example embodiments of the present invention.

FIG. 4 is a second example of the output of a LSS consistent with example embodiments of the present invention.

FIG. 5 is an example of a flow chart of a process consistent with an example embodiment of the present invention.

FIG. 6 is an example of a more detailed flow chart of a process consistent with an example embodiment of the present invention.

FIG. 7 is an example of a flow chart of a process consistent with an example embodiment of the present invention.

DETAILED DESCRIPTION

The present invention embraces a mechanism for compensation of a printer device for long print jobs.

In accord with certain embodiments of the present invention, instead of relying only on a mechanical spring design to control print precision, signals from a label stop sensor (LSS) are used to aid in compensating for drift in the print position.

Many printers utilize a so-called label stop sensor (or black mark sensor) (LSS) is a sensor (e.g., a photoelectric sensor) that aids in controlling the feeding of media through a printer by detecting gaps between labels, or slots or black marks in continuous stock. Referring to FIG. 2, the LSS 40 detects light from a light source 44 that shines through print medium 48 as the print medium advances from platen roller 52 during the process of advancing the print medium through the printer mechanism (actual print mechanism not shown).

Print medium 48 includes a plurality of labels 56 with spaces 60 between the end edge of one label and the start edge of a subsequent label. A printer processor 64 operates to execute processes represented by stored instructions that are stored in memory or storage 68 to control the printing process including control of a printer motor 72 that advances the print medium 48 from platen roller 52. Printer processor also receives input from LSS 40 and operates as will be described later to compensate for the drift in print position.

For printers such as that depicted in FIG. 2, processor 64 generally operates using a command that may be specific to the particular print medium and printer to control the amount of blank media that is to be fed through the print mechanism before the actual printing starts. This setting is called the Start Adjustment (StartAdj). Print media is fed out or pulled back by a specified length of media before the printing of a label, ticket, or other portion of continuous rolled stock starts. In one example embodiment, the value is entered as a number of dots, where a positive value (no leading minus sign) feeds out the media and a negative value (leading minus sign) pulls the media back. (A similar Stop Adjustment is also commonly provided.)

Using this StartAdj setting, the media feed can be controlled so that the printing starts at the top of the label and the media still can be torn off in the gap between two labels. An example of a setup string that sets this value is:

SETUP “DETECTION,FEEDADJ,STARTADJ,−150”

This example string causes the printer to start out a print job by pulling the print medium back by 150 dots. This command provides for alignment of the print job by 150 dots at the beginning of the job. Unfortunately, as a long print job proceeds, the drift described above causes the problem shown in FIG. 1.

In accord with the present teachings, the signal from Label Stop Sensor (LSS) is used to determine how far the printing has drifted and effect a correction to maintain higher accuracy of print position.

The drift the drift that occurs can be detected by periodically inspecting the amount of time it takes from start of the printer motor 72 to detecting a label at the LSS. That time can be compared to the same time measured at the start of the print job to determine how much drift is taking place. The time difference between during retract printing operation is detected by using a label stop sensor by sensing gap or black mark present in the label. The time domain signals from the label stop sensors can be converted into displacement in dots and compensation is applied to compensate for the label drift from desired value at periodic intervals.

In the example embodiments described below, a time difference is detected and is converted to a number of dots by simply multiplying the time by the printer's feed rate and by the printer's vertical resolution. E.g., if the printer feeds 1.5 inches per second, and the vertical resolution is 100 dots per inch, then in two seconds the printer advances the medium by (1.5 in./sec.)*(100 dots/in.)*(2 sec.)=300 dots.

A calculation such as this, using the printer's actual vertical resolution and feed rate can be used to calculate how many dots are advanced. It is noted that in the examples discussed herein the times discussed can be converted to dots at almost any time. Hence, averages discussed as being average times can actually be average numbers of dots by first converting to dots and then averaging. Or, the times can be averaged first and then converted to dots. Similarly, time differences can be calculated as differences in numbers of dots by conversion to dots prior to taking the difference. Those skilled in the art will appreciate that many variations are possible upon consideration of the present teachings.

Referring now to FIG. 3, an example of the output of the LSS is depicted in graphical form. This graph represents the voltage out of the LSS sensor taken at the beginning of a label print job. When the job begins, the motor and sensor turn on at time 80. As the sensor begins to detect either a black mark or the space between adjacent labels, the sensor output begins to change at time 82 rising to a peak and then declining until the space is passed at 84. Time 82 corresponds to light reflecting from the end edge of one label reaching the LSS 40 and time 84 corresponds to light reflecting on the starting edge of the next label. The output of LSS peaks at time 86 midway between labels. The time T(1) as shown is the time between start of the motor and the midpoint between labels. If it is assumed that time T(1) is for the first label or an average of the first few labels, this time can be examined later to determine how much drift has occurred in the labels.

Referring now to FIG. 4, the time between motor start and the center of the label gap can be measured at T(100) for the 100^(th) label in a print job. Time T(1) is shown on FIG. 4 for reference so indicate the difference in time shown as ΔT=T(100)−T(1). In accord with certain embodiments, this time can be converted to dots and used as an correction to the StartAdj for labels after label 100 (e.g., between labels 100 and 200, with another correction at 200).

It has been found advantageous to use the average over a number of labels to determine what correction should be made to the StartAdj parameter. In one example, corrections can be made every 100 labels with the times averaged over the first 10 labels to obtain T(1) and averaged over the last ten labels (90-100) to obtain T(100).

In an exemplary embodiment, the process of adjusting the printer to compensate for print drift is depicted as process 100 of FIG. 5, starting at 102. At 106, an initial reference value of the StartAdj parameter is established and this initial reference value is designated IRS. At 110, an average distance from the motor start to the label for the first M labels is found using the LSS. This can be done by averaging the time for M labels and converting that average time to a number of dots as described above; or, this can be equivalently done by converting the time for each of the first M labels to number of dots and then averaging the number of dots.

At 114, a later average distance from the motor start to the label is found for M later labels (e.g., labels 90-100) in a similar manner. At 118, the difference between the initial average distance from motor start to the label and the later average distance is computed as ΔD expressed in dots in this example. At 122 the initial reference value of StartAdj (IRS) is adjusted to produce a new StartAdj (NS). This provides the compensation that will aid in controlling the drift in print location.

If at 126, the last label has not been reached, the process returns to 114 where after another number of labels (e.g., every 100 labels) the distance is again identified and the NS is adjusted again to continue accounting for drift in print position. Once the last label is reached at 126, the process ends at 130. This process, as well as the others described herein can be carried out by processor 64 utilizing instructions stored in memory/storage 68 to receive input signals from RSS 40 and produce signals controlling printer motor.

FIG. 6 depicts a more detailed flow chart 200 for an example process similar to that which was just described starting at 204. In this example, at 208, the printer system is initialized with an IRS=−180 dots. In this example a label counter C is used and is initialized to 1. Similarly a compensation cycle counter I is initialized to 1. For this example, the adjustment interval L is set to 100 labels—meaning the compensation will be adjusted every 100 labels. In this example, the time between motor start and label as measured using the LSS is averaged over 10 labels so that the first measurement will average the time or distance over the first 10 labels. Similarly, the next time or distance value will be averaged over the last 10 labels before reaching the adjustment interval L (e.g., labels 90-100).

At 212, the print job is started and the IRS designates an initial offset of −180 dots. At 216, the LSS is read to establish time T(1) between the time the motor turns on until the middle (or start or end edge of the label, or a black mark) between labels is reached for the first M labels. In this example, that means that times T(1) through T(10) are measured. The average time TA(1) is computed as the average of times T(1) through T(10) at 220 and that average time TA(1) is converted to average dots as DA(1) at 224. For purposes of an illustrative example, assume that TA(1) converts to DA(1)=21 dots.

At 228, label counter C=L−M and the time T(1+I) is determined by reference to the LSS for the M labels where C=L−M through C=L). In this example, that means time T(91) through T(100). The average time is calculated at 232 as TA(1+I) and this time is converted to dots at 236 as DA(1+I). For purposes of this example, assume that DA(1+I)=DA(2)=46 dots.

At 240, the measured average numbers of dots are used to calculate a new StartAdj NS, where NS=IRS+[DA(1+I)−DA(1)]+ . . . +[DA(4)−DA(1)]+[DA(3)−DA(1)]+[DA(2)−DA(1)]

In the first pass through, this simplifies to NS=IRS+[DA(2)−DA(1)] =−180+[46−21]=−155 dots

This new value of StartAdj NS is then applied as a start adjustment for the next label (e.g., label 100). If the last label is not reached at 248, then I is incremented by 1 at 252 and control returns to 228. This process continues with the NS value being corrected approximately every L labels (e.g., at 100, 200, 300, etc.) When the last label is reached at 248, the process ends at 260.

It should be noted that many variations in this process are possible without departing from the present teachings. For example, in the example of FIG. 6 and based on the prior discussions of FIG. 3 and FIG. 4, one would expect to measure the time between motor start and the center of the pulse from the LSS representing the center of the gap between adjacent labels. One could equally well measure the distance from motor start to the start of the pulse representing the end edge of a label or the end of the pulse representing the start edge of the adjacent label. So long as the distance in time can be accurately measured, the resulting value of ΔT will be the same or approximately the same as if the peak of the pulse is used. Other variations will occur to those skilled in the art upon consideration of the present teachings.

Referring to FIG. 7, the processes described above can be generalized in a process 300 starting at 302. In this process, a method of printer compensation involves at 306 using a label stop sensor (LSS), to detect a time TA(1) associated with an initial label position near the beginning of a print job. “Near” the beginning in many cases means the first several (e.g., the first 10) labels of a print job can be used to represent the initial label position since the diameter of the media roll can be considered near constant over a short distance. At 306, the process uses the label stop sensor to detect a time TA(L) associated with a label position that is L labels (e.g., 100 labels) later in the print job. The value of L can be selected far enough into the print job to detect a drift in the print position, but not so far that the integrity of label L is compromised (e.g., by print shifting outside the bounds of the label. At this point at 316, a computation is made based upon the times TA(1) and TA(L) and a printer media feed rate (and a printer vertical resolution if the distance is to be expressed in vertical dots). The computation involves calculating a difference between the initial label position and the later label position. This distance is generally a distance such as a number of mm or number of dots of vertical resolution. Of course, in all cases, the distance that is used to compensate may be truncated or rounded to the nearest “dot” or otherwise converted to a distance that is within the printer's ability to adjust. At 320, the process compensates a start adjustment factor by the difference between the initial label position and the later label position to account for changes in print position between the first label and the later label. The process ends at 324.

It is noted that while an average of time or distance is used in the embodiments discussed, an actual time or distance associated with a single label could be used if that distance or time can be reliably measured.

To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:

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In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation. 

The invention claimed is:
 1. A method of printer compensation, comprising: using a sensor, detecting a time T(1) associated with a first label position; using the sensor, detecting a time T(L) associated with a second label position that is L labels later in a print job; from at least the times T(1) and T(L) and a media feed rate, calculating a difference between the first label position and the second label position; and compensating an adjustment factor by the difference between the first label position and the second label position to account for changes in print position along a label travel path.
 2. The method according to claim 1, where the calculating comprises converting times T(1) and T(L) to a distance.
 3. The method according to claim 1, where the calculating comprises converting times T(1) and T(L) to a distance represented in printed dots in a feed direction.
 4. The method according to claim 1, where detecting the value T(1) further comprises detecting a sequence of M values T(1) through T(M); and where detecting the value of T(L) further comprises detecting a sequence of M adjacent values about label L.
 5. The method according to claim 4, further comprising averaging the values of T(1) through T(M) to produce TA(1); and averaging the values of the M adjacent values about label L to produce TA(L).
 6. The method according to claim 5, where the calculating comprises from at least the times TA(1) and TA(L), and a feed rate, calculating a difference between the first label position and the second label position.
 7. The method according to claim 4, further comprising: converting the M values T(1) through T(M) to distances D(1) through D(M); and converting the M adjacent values about label L to M distances D(L−M) through D(L).
 8. The method according to claim 4, further comprising averaging the values of D(1) through D(L) to produce DA(1); and averaging the values of the M adjacent values about label L to produce DA(L).
 9. The method according to claim 5, where the calculating comprises using the distances DA(1) and DA(L) to calculate a difference between the first label position and the second label position.
 10. A method of printer compensation, comprising: using a sensor detecting a sequence of time values T(1) through T(M) associated with a first label position; converting the M values T(1) through T(M) to distances D(1) through D(M); using the sensor, detecting times T(L−M) through T(L) associated with a M label positions that are approximately L labels later in the print job; converting the M adjacent values about second label L to L distances D(L−M) through D(L); averaging the values of D(1) through D(M) to produce DA(1); averaging the values of D(L−M) through D(L) to produce DA(L); from at least the distances DA(1) and DA(L), calculating a difference between the first label position and the second label position; and compensating an adjustment factor by the difference between the first label position and the second label position to account for changes in print position along a label travel path.
 11. The method according to claim 10, where the distances are represented in printed dots in a feed direction.
 12. A label printer device, comprising: a sensor that detects a transition between labels; a processor that receives and interprets signals from the sensor; a motor that advances a label medium through the printer; the processor being programmed to: use the sensor to detect a time T(1) associated with a first label position; use the sensor to detect a time T(L) associated with a second label position that is L labels later in the print job; from at least the times T(1) and T(L), and a printer feed rate, calculate a difference between the first label position and the second label position; and compensate an adjustment factor by the difference between the first label position and the second label position to account for changes in print position along a label travel path.
 13. A label printer device according to claim 12 where the transition comprises at least one of a space, black mark, hole, or optical element.
 14. The apparatus according to claim 12, where the processor is programmed to convert times T(1) and T(L) to distances.
 15. The apparatus according to claim 12, where the processor: in detecting the value T(1) is further programmed to detect a sequence of M values T(1) through T(M); and in detecting the value of T(L) is further programmed to detect a sequence of M adjacent values about label L.
 16. The apparatus according to claim 15, where the processor is further programmed to: average the values of T(1) through T(M) to produce TA(1); average the values of the M adjacent values about label L to produce TA(L); and calculate from at least the times TA(1) and TA(L), and a printer media feed rate a difference between the first label position and the second label position.
 17. The apparatus according to claim 15, where the processor is programmed to: convert the M values T(1) through T(M) to distances D(1) through D(M); convert the M adjacent values about label L to M distances D(L−M) through D(L); average the values of D(1) through D(M) to produce DA(1); and average the values of the M adjacent values about label L to produce DA(L).
 18. The apparatus according to claim 12, where the processor is programmed to calculate a difference between the distances DA(1) and DA(L) to calculate a difference between the first label position and the second label position.
 19. The apparatus according to claim 18, where the distances DA(1) and DA(L) are represented as a number of printed dots in a feed direction.
 20. The apparatus according to claim 12, where the processor is programmed to carry out the compensating by adjusting a value of an adjustment factor. 